Differences

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--- internal:proddocs:3271 [2022/04/12 07:05] – [Process] chrissy
+++ internal:proddocs:3271 [2025/08/29 10:54] (current) – david
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 ====== 3271 Build Instructions ======
 <note warning>**The 3271 PCB assembly contains components that are sensitive to electrostatic discharge (ESD) – please make sure you are wearing your wrist strap when handling.**</note>
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 **Fit 200581 Grommet to Fuel Sender Body as shown ensuring correct seating.**
 {{:internal:proddocs:3271-1.png|}}
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 **Browse to the folder S:\Code\Production\3271 Fuel Level Sender\Program AFTER Rev J\
 Then select 3271bootloader.bin**
 {{:internal:proddocs:3271..3.png?600|}}
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 {{:internal:proddocs:3271..4.png?600|}}
 **Now, the blue LED should be on solid.
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 {{:internal:proddocs:3271..7.png?600|}}
 **The tool will now indicate it is programming, it will then show a CRC and PASS, and finally will reboot to application code.**
 {{:internal:proddocs:3271..8.png?600|}}
 **Clean the rods using Amber clean paying attention to the threaded area
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 <note>For Williams 3271-200 mm add two spacers, one at the top and one at the bottom</note>
-**Assemble the Insulator mouldings to the Probe. Check the un-threaded end of the probe for burrs and de-burr if necessary. Slide 200622 Insulators onto the Probe, spacing them approximately 200 mm apart.**
+**Assemble the Insulator mouldings to the Probe. Check the un-threaded end of the probe for burrs and de-burr if necessary. Slide 200622 Insulators onto the Probe, spacing them approximately 200 mm apart.
+**
+<note important>**The outer tube length for Williams is 198mm, the inner rod length is 214mm with CTS 081.
+**</note>
 <note important>Select tightly fitting spacers only – this is critical to prevent them sliding when fully assembled.</note>
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 {{:internal:proddocs:3271-7.png?600|}}
 **DO FUNCTIONAL TEST PRIOR TO POTTING PROCEDURE.**
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   - 	**VERIFY SOFTWARE IS LOADED USING “GETPRODINFO”**
   -  	**ENSURE MODEL ID AND SOFTWARE VERSION ARE CORRECT**
-  - **CLICK GET CAL AND ENSURE CURRENT MEASURED VALUE DOES NOT READ AS 0**
+  -  **CLICK GET CAL AND ENSURE CURRENT MEASURED VALUE DOES NOT READ AS 0**
 ====== Process ======
-  - **Turn on PSU power and plug in the sender.
+<note important>**This is a dry test only to check functionality, The new software is very sensitive and it will fluctuate**</note>
-  - **Open monex 3.12**
+**  -Turn on PSU power and plug in the sender.**
+  - **Open Monex 3.12**
   - **Holding the cable, do an E cal**
-  - **Put the sender in the fuel (up to the 3/4 point on the sender), do an F cal**
+  -** Do an F cal, this will change on the INST**
-  - **Remove the sender in the fuel, give it a gentle shake and do repeat the E cal**
-  - **Put the sender halfway between the end and the 3/4 point in the fuel and check 50% on monex**
+**Check the Blue light is flashing every 2.5 seconds**
 **Before potting, allow the senders to acclimatise in the potting room for a couple of hours. This will reduce the chance of any condensation on the inner sender body.
-. Suitable PPE should be worn when using the two-part Epoxy potting compound.**
+**
+**Suitable PPE should be worn when using the two-part Epoxy potting compound.
-**Warm the compound in the water bath (this should be set to 40 degrees), this takes approximately 10 minutes for the bath to come up to temperature and 5 minutes to warm a bag of compound. Do not warm above this temperature as it will greatly reduce the pot life of the compound.
+Warm the compound in the water bath (this should be set to 40 degrees), this takes approximately 10 minutes for the bath to come up to temperature and 5 minutes to warm a bag of compound. Do not warm above this temperature as it will greatly reduce the pot life of the compound.
 Once warm, work the black potting BEFORE removing the clip and rail – this will help remove any lumps caused by the fillers that have settled over time. Then, place back into the bath for 2 minutes.
 Remove the clip and rail, and mix thoroughly for approximately 2 minutes.**
 {{:internal:proddocs:3271-8.png?600|}}
-<note important>**REMEMBER TO TURN THE WATER BATH OFF ONCE YOU HAVE FINISHED WITH IT** !</note>
-**To avoid air gaps under the PCB and around the wiring, the sender must be at a slight angle – a cotton bud under one side is enough.
+**REMEMBER TO TURN THE WATER BATH OFF ONCE YOU HAVE FINISHED WITH IT !
+To avoid air gaps under the PCB and around the wiring, the sender must be at a slight angle – a cotton bud under one side is enough.
 The compound can then be slowly poured into the lower side, as this allows the potting to fill up level with the board and prevents air pockets.
 Once all air has been removed under the board, you should see a ring of potting all around the outside of the PCB.
-**
-**At this point, the cotton buds can be removed so the sender is now flat and the sender can be topped up.**
-**If any bubbles appear, these can be dispersed by gently using a hot air gun over the surface.**
+At this point, the cotton buds can be removed so the sender is now flat and the sender can be topped up.
+If any bubbles appear, these can be dispersed by gently using a hot air gun over the surface.
+The Potting must now be left overnight to
+Cure and harden.**
+**No epoxy to be visible on the switch and overspill is to be wiped away. Epoxy must be flush to metal surface to avoid creating a recess for any fluid to accumulate when in use.**
-**The Potting must now be left overnight to
-Cure and harden.
-**
-<note important>**No epoxy to be visible on the switch and overspill is to be wiped away. Epoxy must be flush to metal surface to avoid creating a recess for any fluid to accumulate when in use.**</note>
 {{:internal:proddocs:3271-9.png?600|}}
 **Once the Potting has set, the Serial No Label 200303 can be applied. Position symmetrically as shown. The label MUST NOT overlap the switch, LED or metal edges of the body.**
 {{:internal:proddocs:3271-10.png?600|}}
 **Now connect the unit to the Monex system and assign the unit the serial number from the sticker and to do a final test after assembly to make sure the unit is still fully functioning and has not been damaged during the build procedure.
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 <note important>**For Williams use CTS file 081, cut the inner tube to 198 mm and the outer tube to 214 mm.
 Only test on empty and full.**</note>
 {{:internal:proddocs:3271-11.png?600|}}
 **. To Calibrate Sender to empty out of the tank suspended vertically only holding on to the cable.
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 **
 {{:internal:proddocs:3271-12.png|}}
 **With a magnet locate the re calibration place on the top of the unit labelled MAGNET and you will see the blue led remain lit for 2.5seconds (you can repeat this as many times as you like until you are happy that you have set the EMPTY position.
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 **
-{{:internal:proddocs:3271-13.png|}}
+{{:internal:proddocs:3271-13.png|}} {{:internal:proddocs:3271d.jpg?400|}}
 **To calibrate sender to full, turn rotary switch to the ‘F’ position as indicated in the diagram.
-The sender must be dipped into the tube of fuel to where, the fuel must reach the bottom of the threaded part of the sender body – ensure that the tube has sufficient fuel to reach this level.
+The sender must be dipped into the tube of fuel to where, the fuel must reach the bottom of the threaded part of the sender body – ensure that the tube has sufficient fuel to reach this level. Keep clicking the Get Cal button until the Current measured value stops changing. This is a few seconds on a short sender, but could be up to a minute on a 2metre sender. When the value has stopped changing, then calibrate full at the required level. Check that the reading on the big red table goes down very slightly as the sender is raised. DO NOT RESET THE EMPTY, EVEN IF IT READS 2%
 Now as for the empty calibration. With a magnet locate the re-calibration place on the top of the unit labelled MAGNET and you will see the blue led remain lit for 2.5 seconds (you can repeat this as many times as you like until you are happy that you have set the FULL position).
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 This is checked with the GET CAL box which should display the FULL values.**
-{{:internal:proddocs:3271-14.png|}}
+{{:internal:proddocs:3271-14.png|}} {{:internal:proddocs:3271e.jpg?400|}}
 **With calibration complete the rotary dial switch must now be returned to the required instance (0 for a single tank installation). Position as shown in the diagram.
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 Affix the Label squarely to the flats on Sender Body.
 **
 {{:internal:proddocs:3271-15.png|}}
+<note important>**BEFORE PACKING MAKE SURE THERE IS NO FUEL LEFT INSIDE THE SENDER ROD, AS THIS WILL CAUSE THE PACKAGING TO BE FLOODED WITH DIESEL DURING TRANSIT**</note>
 **The Sender is now ready for packing. The user instructions are packed into Poly Bag 200332 along with 1 off Insulator 200602.